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Zira AI Vision / Lighting installation guide

Quality inspection starts with a clear image.

Create a consistent view for your AI camera with a practical four-bar lighting setup, a complete equipment list and a measured commissioning process.

Download installation guide View equipment list PDF / 6 pages / 51 KB
Four light bars mounted around a central camera above an industrial conveyor.
FIG. 01Four-bar lighting around a camera inspection area.

Setup at a glance

Fixture specifications describe the hardware. The lux figure is a starting target you measure on your own line during commissioning.

Layout
4
Perimeter bars, each on its own feed, adjustable independently of the camera
Fixture specification / LEANLED II CLEAR
24 V DC
Supply voltage, ±10%
5700 K
Color temperature, CRI >85

Manufacturer data per bar: approx. 26 W, 4,500 lm, 120° emission, IP54.

Commissioning target
~3,000 lux
Starting target at the product surface

Measure on site. Not a live reading and not a guarantee that four bars reach it.

01The four-bar arrangement

Light the perimeter. Keep the camera fixed.

Product size, camera resolution and the smallest defect you need to see determine the final geometry. There is no universal frame height or rail length.

Four-bar lighting schematic, illustrative layout, not to scale Top view: two light bars run along the conveyor on either side of the product and two run across it, forming a rectangle around a camera that looks straight down at the product. The conveyor moves left to right. Side view: the camera sits above the product, and the bars are aimed down and inward. TOP VIEW CONVEYOR DIRECTION BAR 1 / ALONG CONVEYOR BAR 2 / ALONG CONVEYOR BAR 4ACROSS BAR 3ACROSS CAMERA, LOOKING DOWN - - - CAMERA FIELD OF VIEW SIDE VIEW CAMERA AIM BARS DOWN AND INWARD ILLUSTRATIVE LAYOUT - NOT TO SCALE
Illustrative layout - not to scale.

  1. Fix the camera view first

    Choose working distance and optics so the whole inspection area is visible and the smallest required defect has usable detail. Mount the camera rigidly and mark the accepted position.

  2. Place two bars along, two across

    Two bars run along the conveyor and two run across it, forming a rectangle around the camera view. Aim them down and inward.

  3. Tune edge and corner coverage

    Check the center, edges and corners on your largest product. Corners and perimeter boards are where shortfalls usually show first.

  4. Adjust lights independently of the camera

    Make bar height, spacing and angle adjustable on their own, so tuning the light never moves the accepted camera view.

Close crop of the same installation photo showing the four light bars forming a rectangle around a downward-facing camera.
FIG. 02Crop of the same installation photo (Fig. 01): four bars framing the central camera.
What the evidence supports

A two-lamp test of this fixture was reported without observed flicker. The four-bar rectangle extends that recommendation to improve perimeter coverage, and it must be commissioned on your actual line. Photos document hardware placement, not inspection performance.

02Choose the recipe

One baseline. Two separate trials.

These are not interchangeable lighting solutions. The four-bar setup is the general inspection baseline. Raised nails and wrapped cartons each need their own trial on real product.

Baseline recipe

Pallet QA

Uniform coverage across the full inspection area, with usable detail at the center, edges and corners of the largest pallet.

Setup

  • Four LEANLED II CLEAR bars around the camera view, two along and two across the conveyor.
  • Start at about 3,000 lux at the product surface and measure a nine-point grid.
  • Proposed commissioning criterion: minimum / average ≥ 0.80.
  • Note: strong, even fill can soften the shallow shadows that reveal slightly raised protrusions.

03Equipment list

Exact parts. Clear quantities.

The baseline for one four-bar station. Part numbers are selectable and copyable. This page does not sell or process orders.

Tick items as you source them. Ticks stay in this browser only.

Equipment for one four-bar lighting station: quantity, item and part number, installation note and product link
QtyItem / part numberInstallation noteLink
4light bars LEANLED II CLEAR light bar, 1020 mm111010-06 Each includes flat and swivel bracket pairs. Clear cover, non-cascadable. 24 V DC ±10%, approx. 26 W, 4,500 lm, 5700 K, CRI >85, 120°, IP54. View product
4cables 5 m M12-A to open-lead cable, 4-wire200100-04 One independent feed per lamp. Do not daisy-chain. Verify the actual route length. View product
2power supplies 24 V DC supply, 90 W / 3.8 A, NEC Class 2PIM90.245-L1 100-240 V AC input. Each feeds two lamps in parallel, about 52 W / 2.17 A. Keep the two outputs separate. Do not parallel the supplies. View product
1set Rigid frame, 1515-series T-slot profile 4 perimeter rails plus supports, anchors and matched fasteners. An existing suitable frame may be reused. The fabricator sets rail lengths, spans and loading. View product
8starter allowance Cable-tie mounting blocks12316 Adjust to the actual cable route. Keep cables clear of pinch points, moving parts and the camera view. View product
1per team Light meterLT300 One per commissioning team, or reuse a suitable calibrated meter. View product
Sitedesigned Electrical enclosure and protection Enclosure, DIN rail, terminals, disconnect, circuit protection, cable glands, strain relief. Rated by qualified site electrical personnel. Site-specific

Power arrangement

Two separate regulated 24 V DC supplies, two lamps each. Four lamps total about 104 W, which is more than one 100 VA Class 2 output should carry, so never place all four on a single supply. Confirm polarity, connector pinout and cable capacity against the manuals. No hot-plugging.

Confirm stock, pricing and delivery with the supplier before ordering, and check the label on the delivered fixture.

04Installation

Seven steps, in order.

Fit the largest product and the full inspection view before you finalize the light frame. Protect the line's required clearances and maintenance access.

  1. Step A: Define the inspection area and largest product

    Mark the exact area the camera must see and the biggest product that passes through it, including relevant product heights.

  2. Step B: Fix camera framing and usable defect detail

    Confirm the full area is in view and the smallest required defect is resolved. Avoid relying on digital zoom. Lock and mark the camera mount.

  3. Step C: Mount and aim the bars with the supplied brackets

    Use the included flat or swivel brackets and suitable frame adapters. Two bars along the conveyor, two across, aimed down and inward. Keep at least 10 cm between each emitting surface and any object.

  4. Step D: Connect the independent 24 V supplies

    Qualified electrical personnel complete isolation, protection and fixed wiring. Two supplies, two lamps each, outputs kept separate. Disconnect power before connecting; do not hot-plug.

    Qualified electrical personnel

  5. Step E: Measure illumination

    Take a nine-point reading across the inspection area at the product surface. See commissioning below.

  6. Step F: Tune and lock camera settings

    Set the shortest practical exposure for conveyor motion, low gain, then fix focus, exposure, gain and white balance where supported. Avoid an unverified dimmer in the baseline.

  7. Step G: Validate with actual Zira snapshots

    Review full-resolution frames at production speed before running the diagnostic trial.

A supplemental light fixture mounted on an overhanging support beside industrial machinery, safety guarding and a pallet.
FIG. 03Example of supplemental lighting beside a Zira camera.
Manufacturer limits

Qualified electrical installation only. No hot-plugging. At least 10 cm from the emitting surface to objects. Never cover the fixture with film or cloth. IP54 does not make an installation washdown-rated.

05Commissioning and validation

Measure the light. Then check the image.

Acceptance is based on the product plane and the exact frames Zira captures, at production speed and with the intended exposure and frame rate.

Step 1 Proposed criterion

Nine-point surface measurement

Place the meter sensor in the product surface plane, facing the lights. Record a 3 x 3 grid across the actual inspection area, including corners. Repeat at relevant product heights. Proposed criterion: minimum / average ≥ 0.80, starting from a target of about 3,000 lux.

Enter your nine lux readings, arranged as they sit over the inspection area. Results update as you type.

Your readings, luxWorksheet only. Nothing is sent or saved.

Enter all nine readings to see average, minimum and uniformity.

A lux meter measures illuminance. It does not detect camera-visible LED flicker; check for banding in the snapshots.

Step 2

Actual-image test

Open full-resolution Zira snapshots taken at production speed with the intended exposure and frame rate. Check for:

  • Motion blur on moving product
  • Glare and clipped highlights
  • Dark regions that hide the target, especially corners
  • Banding from light or exposure interaction
  • Dark and light wood, center and edge detail

Fix accepted focus, exposure, gain and white balance. Revalidate after any change to lighting, camera position or settings, or product presentation, and keep training and production imaging conditions the same.

Step 3 Diagnostic, not acceptance

Diagnostic trial

20uniquely numbered defect pallets
5clean controls

Include dark and light wood and defects at the center, edges and corners. Log each pass and review the exact frame the model judged.

If the defect isInvisible, blurred or unresolvedMake an imaging adjustment.
If the defect isClearly visible but missedSend for model review.

This trial is diagnostic, not statistical production acceptance. Agree the final representative acceptance plan and performance targets with the Zira AI team.

FIG. 04Reviewing captured frames: two separate pallet snapshots, shown with their original annotations. Different pallets, not a lighting comparison.

06FAQ

Common questions

Is the LEANLED II CLEAR a diffuse light?

No. Part 111010-06 is the clear-cover version. It suits the general four-bar baseline. For glossy or wrapped product where glare is the problem, trial a shielded hood with diffuse light instead, and revalidate exposure afterward.

Will this setup detect raised nails?

Not on its own, and no detection is guaranteed. Strong, even fill can soften the shallow shadows that reveal slightly raised nails. Run the separate raised-nail trial with directional light and an oblique camera view on real defects before agreeing coverage.

Does this light the underside of the pallet?

No. The four-bar station lights the surface the overhead camera sees. Underside views need their own camera position and their own lighting, commissioned separately.

How do I check illumination and flicker?

Use the light meter for the nine-point illuminance grid. A lux meter does not detect camera-visible flicker, so also review snapshots at the production shutter speed and frame rate for banding or brightness changes. A two-lamp test of this fixture was reported without observed flicker; confirm the same on your four-bar installation. Leave dimmers out of the baseline unless verified.

What should we check at the start of each shift?

Lights on and stable, lenses and protective windows clean, camera view unobstructed, mounts and aim unchanged, and representative test images readable. Keep the lights on during inspection, log lighting faults and recheck after maintenance. IP54 is not a washdown rating, so clean accordingly.

Can I source these parts in my region?

Each item in the equipment list links to a product page. Order by exact part number and confirm stock, pricing and delivery for your region with the supplier.

Take the full guide to the line.

Fixture details, the equipment list, mounting and power notes, the commissioning worksheet and the diagnostic trial, in one printable PDF.

Download installation guide Contact sales
FIG. 04 / Original annotations preserved
Two separate top-down camera snapshots of wooden pallets on a conveyor, each with one board outlined in yellow by the original annotation.